Sierra Series 240 and 241 Innova-Mass™ Multi-Parameter ...€¦ · Series 240/241 Instruction...
Transcript of Sierra Series 240 and 241 Innova-Mass™ Multi-Parameter ...€¦ · Series 240/241 Instruction...
Series 240/241 Instruction Manual Table of Contents
IM-24 0-1
Sierra Series 240 and 241 Innova-Mass™ Multi-Parameter
Vortex Mass Flow Meters
Models 240- V and 241-V
Instruction Manual Part Number: IM-24, Rev. D.3 11/08
CORPORATE HEADQUARTERS 5 Harris Court, Building L Monterey, CA 93940
Phone (831) 373-0200 (800) 866-0200 Fax (831) 373-4402 www.sierrainstruments.com
EUROPE HEADQUARTERS Bijlmansweid 2 1934RE Egmond aan den Hoef The Netherlands
Phone +31 72 5071400 Fax +31 72 5071401
ASIA HEADQUARTERS Room 618, Tomson Centre, Bldg. A
188 Zhang Yang Road Pu Dong New District, Shanghai, P.R.China
Phone: + 8621 5879 8521/22 Fax: +8621 5879 8586
IMPORTANT: This manual is for use with 240/241 Vortex Products purchased February 2008 or later
Table of Contents Series 240/241 Instruction Manual
0-2 IM-24
Customer Notice Unless you have specifically ordered Sierra’s optional O2 cleaning, this flow meter may not be fit for oxygen service. Sierra Instruments, Inc., is not liable for any damage or personal injury, whatsoever, resulting from the use of Sierra Instru-ments standard mass flow meters for oxygen gas. You are responsible for clean-ing the mass flow meter to the degree required for your oxygen flow application.
© COPYRIGHT SIERRA INSTRUMENTS 2008 No part of this publication may be copied or distributed, transmitted, transcribed, stored in a retrieval system, or translated into any human or computer language, in any form or by any means, electronic, mechanical, manual, or otherwise, or disclosed to third parties without the express written permission of Sierra Instruments. The information contained in this manual is subject to change without notice. TRADEMARKS Innova-Flo™ and Innova-Mass™ are trademarks of Sierra Instruments, Inc. Other product and company names listed in this manual are trademarks or trade names of their respec-tive manufacturers.
Series 240/241 Instruction Manual Table of Contents
IM-24 0-3
Table of Contents
Chapter 1 Introduction Innova-Flo™ Vortex Flow Meters ........................................................ 1-1 Using this Manual ......................................................................... 1-1 Note and Safety Information ......................................................... 1-2 Receipt of System Components .................................................... 1-2 Technical Assistance ..................................................................... 1-2 How the Innova-Flo Vortex Flow Meter Operates .............................. 1-3 Velocity Measurement/Pressure Drop ........................................... 1-3 Flow Meter Configurations .................................................................. 1-7
Chapter 2 Installation Installation Overview ........................................................................... 2-1 Flow Meter Installation Requirements .......................................... 2-1 Unobstructed Flow Requirements ................................................. 2-2 Series 240 In-Line Flow Meter Installation ......................................... 2-3 Wafer-Style Flow Meter Installation ............................................. 2-4 Flange-Style Flow Meter Installation ............................................ 2-5 Series 241 Insertion Flow Meter Installation ....................................... 2-6 Cold Tap Guidelines...................................................................... 2-7 Hot Tap Guidelines ....................................................................... 2-8 Flow Meter Insertion ........................................................................... 2-9 Installing Meters with a Compression Connection ..................... 2-10 Installing Meters with a Packing Gland Connection ................... 2-12 Installing Meters (Packing Gland), No Insertion Tool ................ 2-15 Adjusting Meter Orientation .............................................................. 2-17 Display/Keypad Adjustment ....................................................... 2-17 Enclosure Adjustment ................................................................. 2-18 Wiring Connections ........................................................................... 2-19 Input Power Connections ............................................................ 2-19 Pulse Output Connections ........................................................... 2-21 Remote Electronics Wiring ......................................................... 2-22
Chapter 3 Operating Instructions Flow Meter Display/Keypad ................................................................ 3-1 Start Up ................................................................................................ 3-2 Using the Setup Menus ........................................................................ 3-3 Programming the Flow Meter ....................................................... 3-3 Output Menu ................................................................................. 3-4 Display Menu ................................................................................ 3-5 Totalizer Menu .............................................................................. 3-6 Units Menu .................................................................................... 3-7 Diagnostics Menu .......................................................................... 3-8 Calibration Menu .......................................................................... 3-9 Password Menu ........................................................................... 3-10
Table of Contents Series 240/241 Instruction Manual
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Chapter 4 HART Communications Wiring ................................................................................................. 4-1 HART Menus ...................................................................................... 4-2 Fast Key Sequence .............................................................................. 4-3 Fast Key Sequence (continued) .......................................................... 4-4
Chapter 5 Troubleshooting and Repair Hidden Diagnostics Menus .................................................................. 5-1 Column One Hidden Diagnostics Values ...................................... 5-2 Column Two Hidden Diagnostics Values ..................................... 5-3 Analog Output Calibration .................................................................. 5-4 Troubleshooting the Flow Meter ......................................................... 5-4 Symptom: Output at no Flow ........................................................ 5-4 Symptom: Erratic Output .............................................................. 5-4 Symptom: No Output .................................................................... 5-5 Electronics Assembly Replacement ..................................................... 5-6 Returning Equipment to the Factory .................................................... 5-7
Appendix A Product Specifications
Appendix B Glossary
Appendix C ATEX-IECEx
Series 240/241 Instruction Manual Table of Contents
IM-24 0-5
Warnings and Cautions
Warning! Agency approval for hazardous location installations varies between flow meter models. Consult the factory for specific flow meter approvals before any hazardous location instal-lation. For explosion proof installations, you must use solid metal conduit and follow NFPA (or your local code) approved wiring methods. Hot tapping must be performed by a trained professional. U.S. regulations often require a hot tap permit. The manufacturer of the hot tap equipment and/or the contractor perform-ing the hot tap is responsible for providing proof of such a permit. All flow meter connections, isolation valves and fittings for cold/hot tapping must have the same or higher pressure rating as the main pipeline. For Series 241 insertion flow meter installations, an insertion tool must be used for any installation where a flow meter is inserted under pressure greater than 50 psig. To avoid serious injury, DO NOT loosen a compression fitting under pressure. All wiring procedures must be performed with the power Off. Before attempting any flow meter repair, verify that the line is de-pressurized. Always remove main power before disassembling any part of the mass flow meter.
Caution! Calibration must be performed by qualified personnel. Sierra Instruments, Inc., strongly re-commends that you return your flow meter to the factory for calibration. In order to achieve accurate and repeatable performance, the flow meter must be in-stalled with the specified minimum length of straight pipe upstream and downstream of the flow meter’s sensor head. When using toxic or corrosive gases, purge the line with inert gas for a minimum of four hours at full gas flow before installing the flow meter. Wafer-style flow meter gaskets must be carefully aligned to ensure accurate flow mea-surement. For Series 241 insertion flow meter installations, the sensor alignment pointer must point downstream in the direction of flow.
Series 240/241 Instruction Manual Chapter 1 Introduction
IM-24 1-1
Chapter 1 Introduction
Innova-Flo™ Vortex Flow Meters The Sierra Instruments’ Series 240 In-Line and the Series 241 Insertion
Innova-Flo™ Vortex Flow Meters provide a reliable solution for process
flow measurement. From a single entry point in the pipeline, Innova-Flo
meters offer precise measurements of mass or volumetric flow. The ve-
locity sensor reduces the effects of pipeline vibration by incorporating a
unique piezoelectric element that senses the vortex frequency. To extend
rangeability at the low end of flow, the meter’s smart electronics calcu-
lates the Reynolds number (Re) based on constant values of fluid density
and viscosity stored in memory and automatically corrects for any non-
linearity down to Re = 5,000.
Innova-Flo digital electronics allows reconfiguration for most gases, liq-
uids and steam. The instrument is loop powered (12 to 36 VDC) with
two output signals. The pulse output signal is proportional to volumetric
flow rate; the analog linear 4-20 mA signal offers your choice of volu-
metric flow rate or mass flow rate. The mass flow rate is based on a con-
stant value for fluid density stored in the instrument’s memory. The local
keypad/display provides instantaneous flow rate in engineering units or
totalized flow.
The Sierra Series 240 and 241 Innova-Flo Meters simple installation
combines with an easy-to-use interface that provides quick set up, long
term reliability and accurate flow measurement over a wide range of
flows and conditions.
Using This Manual This manual provides the information needed to install and operate the
Series 240 In-Line and Series 241 Insertion Innova-Flo Vortex Flow Me-
ters. The four chapters of this manual cover these areas:
• Chapter 1 includes the introduction and product description
• Chapter 2 provides information needed for installation
• Chapter 3 describes system operation and programming
• Chapter 4 covers troubleshooting and repair
The product specifications are found in Appendix A. Appendix B con-
tains a glossary of terms.
Chapter 1 Introduction Series 240/241 Instruction Manual
1-2 IM-24
Note and Safety Information We use note, caution and warning statements throughout this book to
draw your attention to important information.
Warning!
Caution!
Note
This statement appears with
information that is important to
protect people and equipment
from damage. Pay very close
attention to all warnings that
apply to your application.
This statement appears with
information that is important
for protecting your equipment
and performance. Read and
follow all cautions that apply
to your application.
This statement appears with a
short message to alert you to
an important detail.
Receipt of System Components When receiving a Sierra flow meter, carefully check the outside packing
carton for damage incurred in shipment. If the carton is damaged, notify
the local carrier and submit a report to the factory or distributor. Remove
the packing slip and check that all ordered components are present.
Make sure any spare parts or accessories are not discarded with the
packing material. Do not return any equipment to the factory without
first contacting Sierra Customer Service.
Technical Assistance If you encounter a problem with your flow meter, review the configura-
tion information for each step of the installation, operation and set up
procedures. Verify that your settings and adjustments are consistent with
factory recommendations. Refer to Chapter 4, Troubleshooting, for spe-
cific information and recommendations.
If the problem persists after following the troubleshooting procedures
outlined in Chapter 4, contact Sierra Instruments, Technical Support at
(800) 866-0200 or (831) 373-0200 between 8:00 a.m. and 5:00 p.m.
PST. When calling Technical Support, have the following information
on hand:
• the flow range, serial number and Sierra order number (all
marked on the meter nameplate)
• the problem you are encountering and any corrective action
taken
• application information (gas, pressure, temperature and pip-
ing configuration)
Series 240/241 Instruction Manual Chapter 1 Introduction
IM-24 1-3
How the Innova-Flo Vortex Flow Meter Operates
Figure 1-1. Series 240 In-Line Vortex Flow Meter
Sierra Series 240 and 241 Innova-Flo
™ Vortex Flow Meters use a unique
velocity sensor head to monitor volumetric flow rate. The built-in flow
computer calculates mass flow rate based on a constant value of fluid
density stored in the instrument’s memory. To measure fluid velocity,
the flow meter incorporates a bluff body (shedder bar) in the flow
stream, and the velocity sensor measures the frequency of vortices cre-
ated by the shedder bar. The velocity sensor head is located downstream
of the shedder bar within the flow body.
Velocity Measurement The Innova-Flo vortex velocity sensor is a patented mechanical design
that minimizes the effects of pipeline vibration and pump noise, both of
which are common error sources in flow measurement with vortex flow
meters. The velocity measurement is based on the well-known Von Kar-
man vortex shedding phenomenon. Vortices are shed from a shedder bar,
and the vortex velocity sensor located downstream of the shedder bar
senses the passage of these vortices. This method of velocity measure-
ment has many advantages including inherent linearity, high turndown,
reliability and simplicity.
Chapter 1 Introduction Series 240/241 Instruction Manual
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Vortex Shedding Frequency
Von Karman vortices form downstream of a shedder bar into two dis-
tinct wakes. The vortices of one wake rotate clockwise while those of
the other wake rotate counterclockwise. Vortices generate one at a time,
alternating from the left side to the right side of the shedder bar. Vortices
interact with their surrounding space by over-powering every other
nearby swirl on the verge of development. Close to the shedder bar, the
distance (or wave length) between vortices is always constant and meas-
urable. Therefore, the volume encompassed by each vortex remains con-
stant, as shown below. By sensing the number of vortices passing by the
velocity sensor, the Innova-Flo™
Vortex Flow Meter computes the total
fluid volume.
Vortex shedder bar
Flow
Vortices
Velocity sensor
Constant
wave length
Figure 1-2. Measurement Principle of Vortex Flow Meters
Vortex Frequency Sensing
The velocity sensor incorporates a piezoelectric element that senses the
vortex frequency. This element detects the alternating lift forces pro-
duced by the Von Karman vortices flowing downstream of the vortex
shedder bar. The alternating electric charge generated by the piezoelec-
tric element is processed by the transmitter’s electronic circuit to obtain
the vortex shedding frequency. The piezoelectric element is highly sensi-
tive and operates over a wide range of flows, pressures and temperatures.
Series 240/241 Instruction Manual Chapter 1 Introduction
IM-24 1-5
Re = ρ V D
µ
St = f d
V
Flow Velocity Range
To ensure trouble-free operation, vortex flow meters must be correctly
sized so that the flow velocity range through the meter lies within the
measurable velocity range (with acceptable pressure drop) and the linear
range.
The measurable range is defined by the minimum and maximum velocity
using the following table.
Gas Liquid
Vmin
25
ρ
ft/s 1 ft/s
English ρ (lb/ft3)
Vmax 300 ft/s 30 ft/s Vmin
37
ρ
m/s 0.3 m/s
Metric ρ (kg/m3)
Vmax 91 m/s 9.1 m/s
The pressure drop for series 241 insertion meters is negligible. The
pressure drop for series 240 in-line meters is defined as:
∆P = .00024 ρ V2
English units (∆P in psi, ρ in lb/ft3, V in ft/sec)
∆P = .000011 ρ V2
Metric units (∆P in bar, ρ in kg/m3, V in m/sec)
The linear range is defined by the Reynolds number. The Reynolds num-
ber is the ratio of the inertial forces to the viscous forces in a flowing
fluid and is defined as:
Where
Re = Reynolds Number
ρ = mass density of the fluid being measured
V = velocity of the fluid being measured
D = internal diameter of the flow channel
µ = viscosity of the fluid being measured
The Strouhal number is the other dimensionless number that quantifies
the vortex phenomenon. The Strouhal number is defined as:
Where
St = Strouhal Number
f = frequency of vortex shedding
d = shedder bar width
V = fluid velocity
Chapter 1 Introduction Series 240/241 Instruction Manual
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As shown below, Innova-Flo™
Vortex Flow Meters exhibit a constant
Strouhal number across a large range of Reynolds numbers, indicating a
consistent linear output over a wide range of flows and fluid types. Be-
low this linear range, the intelligent electronics in Innova-Flo automati-
cally corrects for the variation in the Strouhal number. Innova-Flo’s
smart electronics correct for this non-linearity by calculating the Rey-
nolds number based on constant values of the fluid’s density and viscos-
ity stored in the instrument’s memory. Innova-Flo Vortex Flow Meters
automatically correct down to a Reynolds number of 5,000.
0.3 0.2 0.1 0.0
3 410
Linear range
Reynolds Number, Re
Str
ou
ha
l N
um
be
r, S
t
105
10 108
106
107
5000
Corrected range
Figure 1-3. Reynolds Number Range for the Innova-Flo Meter
Series 240/241 Instruction Manual Chapter 1 Introduction
IM-24 1-7
Flow Meter Configurations Innova-Flo™ Vortex Flow Meters are available in two configurations:
• Series 240 in-line flow meter (replaces a section of the pipeline)
• Series 241 insertion flow meter (requires a “cold” tap or a “hot” tap
into an existing pipeline)
Both the in-line and insertion configurations are similar in that they both
use identical electronics and have similar sensor heads. Besides installa-
tion differences, the main difference between an in-line flow meter and
an insertion flow meter is their method of measurement.
For an in-line vortex flow meter, the shedder bar is located across the en-
tire diameter of the flow body. Thus, the entire pipeline flow is included
in the vortex formation and measurement. The sensing head, which di-
rectly measures velocity is located just downstream of the shedder bar.
An insertion vortex flow meter has its sensing head at the end of a 0.750
inch diameter tubular stem. The stem is inserted into the pipe until the
sensing head is properly located in the pipe’s cross section. The sensing
head fits through any entry port with an 1.875 inch minimum internal di-
ameter.
The sensing head of an insertion vortex flow meter directly monitors the
velocity at a point in the cross-sectional area of a pipe, duct, or stack (re-
ferred to as “channels”). The velocity at a point in the pipe varies as a
function of the Reynolds number. The insertion vortex flow meter com-
putes the Reynolds number based on constant values of the fluid’s density
and viscosity stored in its memory and then computes the total flow rate in
the channel. The output signal of insertion meters is the total flow rate in
the channel. The accuracy of the total flow rate computation depends on
adherence to the piping installation requirements given in Chapter 2. If ad-
herence to those guidelines cannot be met, contact the factory for specific
installation advice.
Flow Meter Electronics
Innova-Flo electronics are available mounted directly to the flow body,
or remotely mounted. The electronics housing may be used indoors or
outdoors, including wet environments. The instrument requires 4-20 mA
loop power (12 to 36 VDC). One analog output signal is available for
your choice of volumetric flow rate or mass flow rate. A pulse output is
available for totalization.
Chapter 1 Introduction Series 240/241 Instruction Manual
1-8 IM-24
The meter includes a local 2 x 16 character LCD display housed within
the enclosure. Local operation and reconfiguration is accomplished us-
ing six push buttons. For hazardous locations, the six push buttons can
be operated through the sealed enclosure using a hand-held magnet,
thereby not compromising the integrity of the hazardous location certifi-
cation.
The electronics include nonvolatile memory that stores all configuration
information. The memory allows the flow meter to function immediately
upon power up, or after an interruption in power.
Series 240/241 Instruction Manual Chapter 2 Installation
IM-24 2-1
Chapter 2 Installation
Installation Overview Innova-Flo™ meter installations are simple and straightforward. Both the
Series 240 In-Line and Series 241 Insertion type flow meter installations are
covered in this chapter. After reviewing the installation requirements given
below, see page 2-3 for Series 240 installation instructions. See page 2-6 for
Series 241 installation instructions. Wiring instructions begin on page 2-19.
Flow Meter Installation Requirements Before installing the flow meter, verify the installation site allows for these
considerations:
1. Line pressure and temperature will not exceed the flow meter
rating.
2. The location meets the required minimum number of pipe di-
ameters upstream and downstream of the sensor head as illus-
trated Figure 2-1.
3. Safe and convenient access with adequate overhead clearance
for maintenance purposes.
4. Verify that the cable entry into the instrument meets the spe-
cific standard required for hazardous area installations.
5. For remote installations, verify the supplied cable length is suf-
ficient to connect the flow meter sensor to the remote electron-
ics.
Also, before installation check your flow system for anomalies such as:
• leaks
• valves or restrictions in the flow path that could create disturbances in
the flow profile that might cause unexpected flow rate indications
Warning!
Consult the flow meter name-
plate for specific flow meter
approvals before any hazard-
ous location installation.
Chapter 2 Installation Series 240/241 Instruction Manual
2-2 IM-24
Unobstructed Flow Requirements Select an installation site that will minimize possible distortion in the flow
profile. Valves, elbows, control valves and other piping components may
cause flow disturbances. Check your specific piping condition against the
examples shown below. In order to achieve accurate and repeatable perform-
ance install the flow meter using the recommended number of straight run
pipe diameters upstream and downstream of the sensor.
Note: For liquid applications in vertical pipes, avoid installing with flow in
the downward direction because the pipe may not be full at all points.
Choose to install the meter with flow in the upward direction if possible.
Flow meter
A B
Example 1. One 90° elbow before meter
C' Flow meter
A B
C
Flow conditioner (if used)
Example 2. Two 90° elbows before meter in one plane
C' Flow meter
A B
C
Flow conditioner (if used)
Example 3. Two 90° elbows before meter out of plane (if three 90° bends present, double recommended length)
Flow meter
A B
Example 4. Reduction before meter
C' C
Flow conditioner (if used)
Flow meter
A B
C' C
Flow conditioner (if used)
Example 5. Expansion before meter
Example 6. Regulator or valve partially closed before meter (If valve is always wide open, base length requirements on fitting directly preceding it)
Flow meter
A B
C' C
Flow conditioner (if used)
Minimum Required Upstream Diameters
Minimum Required Downstream Diameters
No Flow Conditioner
With Flow Conditioner
No Flow Conditioner
With Flow Conditioner
Example A A C C´ B B 1 10 D N/A N/A N/A 5 D 5 D 2 15 D 10 D 5 D 5 D 5 D 5 D 3 25 D 10 D 5 D 5 D 10 D 5 D 4 10 D 10 D 5 D 5 D 5 D 5 D 5 20 D 10 D 5 D 5 D 5 D 5 D 6 25 D 10 D 5 D 5 D 10 D 5 D
D = Internal diameter of channel. N/A = Not applicable
Figure 2-1. Recommended Pipe Length Requirements for Installation, Series 240 and 241
Series 240/241 Instruction Manual Chapter 2 Installation
IM-24 2-3
Series 240 In-Line Flow Meter Installation Install the Series 240 In-Line Flow Meter between two conventional pipe
flanges as shown in Figures 2-3 and 2-4. Table 2-1 provides the recom-
mended minimum stud bolt lengths for wafer-style meter body size and dif-
ferent flange ratings.
The meter inside diameter is equal to the same size nominal pipe ID in
schedule 80. For example, a 2” meter has an ID of 1.939” (2” schedule 80).
Do not install the meter in a pipe with an inside diameter smaller than
the inside diameter of the meter. For schedule 160 and higher pipe, a spe-
cial meter is required. Consult the factory before purchasing the meter.
Series 240 Meters require customer-supplied gaskets. When selecting gasket
material make sure that it is compatible with the process fluid and pressure
ratings of the specific installation. Verify that the inside diameter of the gas-
ket is larger than the inside diameter of the flow meter and adjacent piping.
If the gasket material extends into the flow stream, it will disturb the flow
and cause inaccurate measurements.
Flange Bolt Specifications
Stud Bolt Lengths for Each Flange Rating (inches)
Line Size Class 150 Class 300 Class 600
1 inch 6.00 7.00 7.50 1.5 inch 6.25 8.50 9.00 2 inch 8.50 8.75 9.50 3 inch 9.00 10.00 10.50 4 inch 9.50 10.75 12.25
Table 2-1. Minimum Recommended Stud Bolt Lengths for Wafer Meters
The required bolt load for sealing the gasket joint is affected by several ap-
plication-dependent factors, therefore the required torque for each applica-
tion may be different. Refer to the ASME Pressure Vessel Code guidelines
for bolt tightening standards.
1
2
34
1
2
34
5
6 7
8
15
9
3
7
112
6
10
4
8
12
4-bolt 8-bolt 12-bolt
Figure 2-2. Flange Bolt Torquing Sequence
Chapter 2 Installation Series 240/241 Instruction Manual
2-4 IM-24
Wafer-Style Flow Meter Installation Install the wafer-style meter between two conventional pipe flanges of the
same nominal size as the flow meter. If the process fluid is a liquid, make
sure the meter is located where the pipe is always full. This may require lo-
cating the meter at a low point in the piping system. Note: Vortex flow me-
ters are not suitable for two-phase flows (i.e., liquid and gas mixtures). For
horizontal pipelines having a process temperature above 300° F, mount the
meter at a 45 or 90-degree angle to avoid overheating the electronics enclo-
sure. To adjust the viewing angle of the enclosure or display/keypad, see
page 2-17.
Figure 2-3. Wafer-Style Flow Meter Installation
When installing the meter make sure the section marked “inlet” is positioned up-
stream of the outlet, facing the flow. This ensures that the sensor head is posi-
tioned downstream of the vortex shedder bar and is correctly aligned to the flow.
Installing the meter opposite this direction will result in completely inaccurate
flow measurement. To install the meter:
1. Turn off the flow of process gas, liquid or steam. Verify that the line is
not pressurized. Confirm that the installation site meets the required
minimum upstream and downstream pipe diameters.
2. Insert the studs for the bottom side of the meter body between the pipe
flanges. Place the wafer-style meter body between the flanges with the end
stamped “inlet” facing flow. Center the meter body inside the diameter
with respect to the inside diameter of the adjoining piping.
3. Position the gasket material between the mating surfaces. Make sure both
gaskets are smooth and even with no gasket material extending into the
flow profile. Obstructions in the pipeline will disturb the flow and cause
inaccurate measurements.
4. Place the remaining studs between the pipe flanges. Tighten the nuts in the
sequence shown in Figure 2-2. Check for leaks after tightening the flange
bolts.
Caution!
When using toxic or cor-
rosive gases, purge the
line with inert gas for a
minimum of four hours
at full gas flow before
installing the flow meter.
Series 240/241 Instruction Manual Chapter 2 Installation
IM-24 2-5
Flange-Style Flow Meter Installation Install the flange-style meter between two conventional pipe flanges of the
same nominal size as the flow meter. If the process fluid is a liquid, make
sure the meter is located where the pipe is always full. This may require lo-
cating the meter at a low point in the piping system. Note: Vortex flow me-
ters are not suitable for two-phase flows (i.e., liquid and gas mixtures). For
horizontal pipelines having a process temperature above 300° F, mount the
meter at a 45 or 90-degree angle to avoid overheating the electronics enclo-
sure. To adjust the viewing angle of the enclosure or display/keypad, see
page 2-17.
Figure 2-4. Flange-Style Flow Meter Installation
When installing the meter make sure the flange marked “inlet” is positioned up-
stream of the outlet flange, facing the flow. This ensures that the sensor head is
positioned downstream of the vortex shedder bar and is correctly aligned to the
flow. Installing the meter opposite this direction will result in completely inaccu-
rate flow measurement. To install the meter:
1. Turn off the flow of process gas, liquid or steam. Verify that the line is
not pressurized. Confirm that the installation site meets the required
minimum upstream and downstream pipe diameters.
2. Seat the meter level and square on the mating connections with the flange
marked “inlet” facing the flow. Position a gasket in place for each side.
Make sure both gaskets are smooth and even with no gasket material extend-
ing into the flow profile. Obstructions in the pipeline will disturb the flow
and cause inaccurate measurements.
3. Install bolts in both process connections. Tighten the nuts in the sequence
shown in Figure 2-2. Check for leaks after tightening the flange bolts.
Caution!
When using toxic or cor-
rosive gases, purge the
line with inert gas for a
minimum of four hours
at full gas flow before
installing the flow meter.
Chapter 2 Installation Series 240/241 Instruction Manual
2-6 IM-24
Series 241 Insertion Flow Meter Installation Prepare the pipeline for installation using either a cold tap or hot tap method
described on the following pages. Refer to a standard code for all pipe tap-
ping operations. The following tapping instructions are general in nature and
intended for guideline purposes only. Before installing the meter, review the
mounting position and isolation value requirements given below.
Mounting Position
Allow clearance between the electronics enclosure top and any other ob-
struction when the meter is fully retracted.
Isolation Valve Selection
An isolation valve is available as an option with Series 241 meters. If you
supply the isolation valve, it must meet the following requirements:
1. A minimum valve bore diameter
of 1.875 inches is required, and
the valve’s body size should be
two inches. Normally, gate
valves are used.
2. Verify that the valve’s body and
flange rating are within the flow
meter’s maximum operating
pressure and temperature.
3. Choose an isolation valve with
at least two inches existing between the flange face and the gate portion
of the valve. This ensures that the flow meter’s sensor head will not in-
terfere with the operation of the isolation valve.
1.875-inch min.
valve bore
2-inch min.
2-inch
valve size
Isolation Valve Requirements
Series 240/241 Instruction Manual Chapter 2 Installation
IM-24 2-7
Cold Tap Guidelines Refer to a standard code for all pipe tapping operations. The following tap-
ping instructions are general in nature and intended for guideline purposes
only.
1. Turn off the flow of process gas, liquid or steam. Verify that the line is
not pressurized.
2. Confirm that the installation site meets the minimum upstream and
downstream pipe diameter requirements. See Figure 2-1.
3. Use a cutting torch or sharp cutting tool to tap into the pipe. The pipe
opening must be at least 1.875 inches in diameter. (Do not attempt to in-
sert the sensor probe through a smaller hole.)
4. Remove all burrs from the tap. Rough edges may cause flow profile dis-
tortions that could affect flow meter accuracy. Also, obstructions could
damage the sensor assembly when inserting into the pipe.
5. After cutting, measure the thickness of the cut-out and record this num-
ber for calculating the insertion depth.
6. Weld the flow meter pipe connec-
tion on the pipe. Make sure this
connection is within ± 5° perpen-
dicular to the pipe centerline.
7. Install the isolation valve (if
used).
8. When welding is complete and all fittings are installed, close the isola-
tion valve or cap the line. Run a static pressure check on the welds. If
pressure loss or leaks are detected, repair the joint and re-test.
9. Connect the meter to the pipe process connection.
10. Calculate the sensor probe insertion depth as described on the following
pages. Insert the sensor probe into the pipe.
Caution!
When using toxic or
corrosive gases, purge
the line with inert gas
for a minimum of four
hours at full gas flow
before installing the
flow meter.
Warning!
All flow meter connec-
tions, isolation valves
and fittings for cold tap-
ping must have the same
or higher pressure rating
as the main pipeline.
Chapter 2 Installation Series 240/241 Instruction Manual
2-8 IM-24
Hot Tap Guidelines Refer to a standard code for all pipe tapping operations. The following tap-
ping instructions are general in nature and intended for guideline purposes
only.
1. Confirm that the installation site meets the minimum upstream and
downstream pipe diameter requirements.
2. Weld a two inch mounting adapter on the pipe. Make sure the mounting
adapter is within ± 5° perpendicular to the pipe centerline (see previous
page). The pipe opening must be at least 1.875 inches in diameter.
3. Connect a two inch process connection on the mounting adapter.
4. Connect an isolation valve on the process connection. The valve’s full
open bore must be at least 1.875 inches in diameter.
5. Hot tap the pipe.
6. Close the isolation valve. Run a static pressure check on the welds. If
pressure loss or leaks are detected, repair the joint and re-test.
7. Connect the flow meter to the isolation valve.
8. Calculate the sensor probe insertion depth as described on the following
pages. Insert the sensor probe assembly into the pipe.
Check upstream and downstream piping requirements
Weld mounting adapter
Connect process connection (flange or NPT)
Connect isolation valve
Test for leaks, purge pipe
Hot tap pipe
Connect meter to valve, calculate insertion depth, install flow meter
FLOW
Figure 2-5. Hot Tap Sequence
Warning!
Hot tapping must be
performed by a trained
professional. US. regula-
tions often require a hot
tap permit. The manufac-
turer of the hot tap
equipment and/or the
contractor performing the
hot tap is responsible for
providing proof of such a
permit.
Warning!
All flow meter connec-
tions, isolation valves
and fittings for hot tap-
ping must have the same
or higher pressure rating
as the main pipeline.
Series 240/241 Instruction Manual Chapter 2 Installation
IM-24 2-9
Flow Meter Insertion The sensor head must be properly positioned in the pipe. For this reason, it is
important that insertion length calculations are carefully followed. A sensor
probe inserted at the wrong depth in the pipe will result in inaccurate read-
ings.
Insertion flow meters are applicable to pipes 2 inch and larger. For pipe sizes
ten inches and smaller, the centerline of the meter’s sensing head is located at
the pipe’s centerline. For pipe sizes larger than ten inches, the centerline of
the sensing head is located in the pipe’s cross section five inches from the in-
ner wall of the pipe; i.e., its “wetted” depth from the wall to the centerline of
the sensing head is five inches.
Insertion flow meters are available in three probe lengths:
Standard Probe configuration is used with most flow meter process connec-
tions. The length, S, of the stem is 29.47 inches.
Compact Probe configuration is used with compression fitting process con-
nections. The length, S, of the stem is 13.1 inches.
12-Inch Extended Probe configuration is used with exceptionally lengthy
flow meter process connections. The length, S, of the stem is 41.47 inches.
Use the Correct Insertion Formula
Depending on your flow meter’s process connection, use the applicable in-
sertion length formula and installation procedure as follows:
• Flow meters with a compression type connection (NPT or flanged) fol-
low the instructions beginning on page 2-10.
• Flow meters with a packing gland type connection (NPT or flanged) con-
figured with an insertion tool, follow the instructions beginning on page
2-12.
• Flow meters with a packing gland type connection (NPT or flanged)
without an insertion tool, follow the instructions beginning on page 2-
15.
Warning!
An insertion tool must be
used for any installation
where a flow meter is
inserted under pressure
greater than 50 psig.
Chapter 2 Installation Series 240/241 Instruction Manual
2-10 IM-24
Installing Flow Meters with a Compression Connection* Use the following formula to determine insertion length for flow meters
(NPT and flanged) with a compression process connection. The installation
procedure is given on the next page.
Insertion Length Formula
I = S – F – R – t
Where:
I = Insertion length.
S = Stem length – the distance from the center of the sensor head to the base of the
enclosure adapter (S = 29.47 inches for standard probes; S = 13.1 inches for
compact; S = 41.47 inches for 12-inch extended).
F = Distance from the raised face of the flange or top of NPT stem housing to the
outside of the pipe wall.
R = Pipe inside diameter ÷ 2 for pipes ten inches and smaller.
R = Five inches for pipe diameters larger than ten inches. t = Thickness of the pipe wall. (Measure the disk cut-out from the tapping proce-
dure or check a piping handbook for thickness.)
Figure 2-6. Insertion Calculation (Compression Type)
Example:
To install a Series 241 meter with a standard probe (S = 29.47 inches) into a 14
inch schedule 40 pipe, the following measurements are taken:
F = 3 inches
R = 5 inches
t = 0.438 inches
The insertion length for this example is 21.03 inches. Insert the stem through the fit-
ting until an insertion length of 21.03 inches is measured with a ruler.
*All dimensions are in inches
Series 240/241 Instruction Manual Chapter 2 Installation
IM-24 2-11
Insertion Procedure for Meters with a Compression Connection
Figure 2-7. Flow Meter with Compression Type Fitting
1. Calculate the required sensor probe insertion length.
2. Fully retract the stem until the sensor head is touching the bottom of the
stem housing. Slightly tighten the compression nut to prevent slippage.
3. Bolt or screw the flow meter assembly into the process connection. Use
Teflon tape or pipe sealant to improve the seal and prevent seizing on NPT
styles.
4. Hold the meter securely while loosening the compression fitting. Insert
the sensor into the pipe until the calculated insertion length, I, is meas-
ured between the base of the enclosure adapter and the top of the stem
housing, or to the raised face of the flanged version. Do not force the
stem into the pipe.
5. Align the sensor head using the sensor alignment pointer. Adjust the align-
ment pointer parallel to the pipe and pointing downstream.
6. Tighten the compression fitting to lock the stem in position. When the
compression fitting is tightened, the position is permanent.
Caution!
The sensor alignment
pointer must point
downstream, in the
direction of flow.
Warning!
To avoid serious injury,
DO NOT loosen the
compression fitting
under pressure.
Chapter 2 Installation Series 240/241 Instruction Manual
2-12 IM-24
Installing Flow Meters with a Packing Gland Connection* Use the formula below to determine the insertion depth for flow meters
(NPT and flanged) equipped with an insertion tool. To install, see the next
page for instructions for meters with a permanent insertion tool. For meters
with a removable insertion tool, see page 2-14.
Insertion Length Formula
I = F + R + t – 1.35
Where:
I = Insertion length.
F = Distance from the raised face of the flange or top of the
process connection for NPT style meters to the top out-
side of the process pipe.
R = Pipe inside diameter ÷ 2 for pipes ten inches & smaller.
R = Five inches for pipe diameters larger than ten inches.
t = Thickness of the pipe wall. (Measure the disk cut-out
from the tapping procedure or check a piping handbook
for thickness.)
Figure 2-8. Insertion Calculation (Meters with Insertion Tool)
Example 1: Flange Style Meters:
To install a Series 241 Flow Meter into a 14 inch schedule 40 pipe, the fol-
lowing measurements are taken:
F = 12 inches
R = 5 inches
t = 0.438 inches
The example insertion length is 16.09 inches.
Example 2: NPT Style Meters:
The length of thread engagement on the NPT style meters is also subtracted
in the equation. The length of the threaded portion of the NPT meter is 1.18
inches. Measure the thread portion still showing after the installation and
subtract that amount from 1.18 inches. This gives you the thread engagement
length. If this cannot be measured use .55 inch for this amount.
F = 12 inches
R = 5 inches
t = 0.438 inches
The example insertion length is 15.54 inches.
*All dimensions are in inches.
Series 240/241 Instruction Manual Chapter 2 Installation
IM-24 2-13
Insertion Procedure for Flow Meters with Permanent Insertion Tool
Figure 2-9. Flow Meter with Permanent Insertion Tool
1. Calculate the required sensor probe insertion length (see previous page).
Measure from the depth marker arrow down the stanchion and scribe a
mark at the calculated insertion depth.
2. Fully retract the flow meter until the sensor head is touching the bottom
of the stem housing. Attach the meter assembly to the two inch full-port
isolation valve, if used. Use Teflon tape or pipe sealant to improve seal
and prevent seizing on NPT style.
3. Loosen the two packing gland nuts on the stem housing of the meter.
Loosen the stem lock bolt adjacent to the sensor alignment pointer. Align
the sensor head using the sensor alignment pointer. Adjust the alignment
pointer parallel to the pipe and pointing downstream. Tighten the stem
lock bolt to secure the sensor position.
4. Slowly open the isolation valve to the full open position. If necessary,
slightly tighten the two packing gland nuts to reduce the leakage around
the stem.
5. Turn the insertion tool handle clockwise to insert the sensor head into
the pipe. Continue until the top of the upper retractor bracket aligns with
the insertion length position scribed on the stanchion. Do not force the
stem into the pipe.
6. Tighten the packing gland nuts to stop leakage around the stem. Do not
torque over 20 ft-lb.
Caution!
The sensor alignment
pointer must point
downstream, in the
direction of flow.
Note
If line pressure is above
500 psig, it could require
up to 25 ft lb of torque to
insert the flow meter.
Do not confuse this with
possible interference
in the pipe.
Chapter 2 Installation Series 240/241 Instruction Manual
2-14 IM-24
Insertion Procedure for Flow Meters with Removable Insertion Tool
Figure 2-10. Flow Meter with Removable Insertion Tool
1. Calculate the required sensor probe insertion length. Measure from the
depth marker arrow down the stanchion and scribe a mark at the calcu-
lated insertion depth.
2. Fully retract the flow meter until the sensor head is touching the bottom
of the stem housing. Attach the meter assembly to the two inch full-port
isolation valve, if used. Use Teflon tape or pipe sealant to improve seal
and prevent seizing on NPT style.
3. Remove the two top stem clamp nuts and loosen two stem clamp bolts.
Slide the stem clamp away to expose the packing gland nuts.
4. Loosen the two packing gland nuts. Loosen the stem lock bolt adjacent
to the sensor alignment pointer. Align the sensor head using the sensor
alignment pointer. Adjust the alignment pointer parallel to the pipe and
pointing downstream. Tighten the stem lock bolt to secure the sensor po-
sition.
5. Slowly open the isolation valve to the full open position. If necessary,
slightly tighten the two packing gland nuts to reduce the leakage around
the stem.
6. Turn the insertion tool handle clockwise to insert the stem into the pipe.
Continue until the top of the upper retractor bracket lines up with the in-
sertion length mark scribed on the stanchion. Do not force the stem into
the pipe.
Caution!
The sensor alignment
pointer must point
downstream, in the
direction of flow.
Note
If line pressure is above
500 psig, it could require
up to 25 ft lb of torque to
insert the flow meter.
Do not confuse this with
possible interference
in the pipe.
Series 240/241 Instruction Manual Chapter 2 Installation
IM-24 2-15
7. Tighten the packing gland nuts to stop leakage around the stem. Do not
torque over 20 ft-lbs.
8. Slide the stem clamp back into position. Torque stem clamp bolts to 15
ft-lbs. Replace the stem clamp nuts and torque to 10-15 ft-lbs.
9. Attach the safety chain from the stem clamp to the hook on the enclosure
adapter at the nearest link. To separate the insertion tool from the flow
meter, remove four socket head cap bolts securing the upper and lower re-
tractor brackets. Remove the insertion tool.
Installation of Meters with Packing Gland Connection (No Insertion Tool)* Use the following formula to determine insertion depth for meters with a
packing gland connection (NPT and flanged) without an insertion tool.
Insertion Length Formula
I = S – F – R – t
Where:
I = Insertion length.
S = Stem length – the distance from the center
of the sensor head to the base of the enclo-
sure adapter (S = 29.47 inches for standard
probes; S = 41.47 inches for 12 inch ex-
tended probes).
F = Distance from the raised face of the flange
or top of NPT stem housing to the outside
of the pipe wall.
R = Pipe inside diameter ÷ 2 for pipes ten
inches & smaller.
R = Five inches for pipe diameters larger than
ten inches.
t = Thickness of the pipe wall. (Measure the
disk cut-out from the tapping procedure or
check a piping handbook for thickness.)
Figure 2-11. Insertion Calculation (Meters without Insertion Tool)
Example:
To install a Series 241 Flow Meter with a standard probe (S = 29.47) into a
14 inch schedule 40 pipe, the following measurements are taken:
F = 3 inches
R = 5 inches
t = 0.438 inches
The example insertion length is 21.03 inches.
*All dimensions are in inches.
Chapter 2 Installation Series 240/241 Instruction Manual
2-16 IM-24
Insertion Procedure for Flow Meters with No Insertion Tool (Packing Gland Connection)
1. Calculate the required sensor probe insertion length.
2. Fully retract the stem until the sensor head is touching the bottom of the
stem housing. Remove the two top stem clamp nuts and loosen two stem
clamp bolts. Slide the stem clamp away to expose the packing gland nuts.
Loosen the two packing gland nuts.
3. Align the sensor head using the sensor alignment pointer. Adjust the
alignment pointer parallel to the pipe and pointing downstream.
4. Insert the sensor head into the pipe until insertion length, I, is achieved.
Do not force the stem into the pipe.
5. Tighten the packing gland nuts to stop leakage around the stem. Do not
torque over 20 ft-lbs.
6. Slide the stem clamp back into position. Torque stem clamp bolts to 15
ft-lbs. Replace the stem clamp nuts and torque to 10-15 ft-lbs.
Warning!
The line must be
less than 50 psig
for installation.
Caution!
The sensor alignment
pointer must point
downstream, in the
direction of flow.
Series 240/241 Instruction Manual Chapter 2 Installation
IM-24 2-17
Adjusting Meter Orientation Depending on installation requirements, you may need to adjust the meter
orientation. There are two adjustments available. The first rotates the posi-
tion of the LCD display/keypad and is available on both in-line and insertion
meters. The second is to rotate the enclosure position. This adjustment is
only allowed on Series 240 In-Line meters.
Display/Keypad Adjustment (All Meters)
Figure 2-12. Display/Keypad Viewing Adjustment
The electronics boards are electrostatically sensitive. Wear a grounding wrist
strap and make sure to observe proper handling precautions required for
static-sensitive components. To adjust the display:
1. Disconnect power to the flow meter.
2. Loosen the small set screw which secures the electronics enclosure. Un-
screw and remove the cover.
3. Loosen the 4 captive screws.
4. Carefully pull the display/microprocessor board away from the meter
standoffs. Make sure not to damage the connected ribbon cable.
5. Rotate the display/microprocessor board to the desired position. Maxi-
mum turn, two positions left or two positions right (180-degrees).
6. Align the board with the captive screws. Check that the ribbon cable is
folded neatly behind the board with no twists or crimps.
7. Tighten the screws. Replace the cover and set screw. Restore power to
the meter.
Chapter 2 Installation Series 240/241 Instruction Manual
2-18 IM-24
Enclosure Adjustment (Series 240 Only)
Figure 2-13. Enclosure Viewing Adjustment
To avoid damage to the sensor wires, do not rotate the enclosure beyond
180-degrees from the original position. To adjust the enclosure:
1. Remove power to the flow meter.
2. Loosen the three set screws shown above. Rotate the display to the de-
sired position (maximum 180-degrees).
3. Tighten the three set screws. Restore power to the meter.
Series 240/241 Instruction Manual Chapter 2 Installation
IM-24 2-19
Wiring Connections The NEMA 4X enclosure contains an integral wiring compartment with one
dual strip terminal block (located in the smaller end of the enclosure). Two
3/4-inch female NPT conduit entries are available for separate power and
signal wiring. For all hazardous area installations, make sure to use an
agency-approved fitting at each conduit entry. If conduit seals are used, they
must be installed within 18 inches (457 mm) of the enclosure.
Input Power Connections To access the wiring terminal blocks, locate and loosen the small set screw
which locks the small enclosure cover in place. Unscrew the cover to expose
the terminal block.
DC Power Wiring
Connect 4-20 mA loop power (12 to 36 VDC) to the +Pwr and –Pwr termi-
nals on the terminal block. Torque all connections to 4.43 to 5.31 in-lbs (0.5
to 0.6 Nm). The DC power wire size must be 20 to 10 AWG with the wire
stripped 1/2 inch (14 mm). The nominal voltage required to operate the 4-20
mA loop is 12 volts at the meter. The 4-20 mA loop is optically isolated
from the flow meter electronics.
Figure 2-14. DC Power Connections
Warning!
To avoid potential electric
shock, follow National Electric
Code safety practices or your
local code when wiring this
unit to a power source and to
peripheral devices. Failure to
do so could result in injury or
death. All wiring procedures
must be performed with the
power off.
Chapter 2 Installation Series 240/241 Instruction Manual
2-20 IM-24
4-20 mA Output Connections The Innova-Flo meter has a single 4-20 mA loop. The 4-20 mA loop current
is controlled by the meter electronics. The electronics must be wired in se-
ries with the sense resistor or current meter. The current control electronics
require 12 volts at the input terminals to operate correctly.
The maximum loop resistance (load) for the current loop output is depend-
ent upon the supply voltage and is given in Figure 2-16. The 4-20 mA loop
is optically isolated from the flow meter electronics.
Rload is the total resistance in the loop, including the wiring resistance (Rload =
Rwire + Rsense ). To calculate Rmax, the maximum Rload for the loop, use the
maximum loop current, 20 mA. The voltage drop in the loop due to resis-
tance is 20 mA times Rload and this drop is subtracted from the input voltage.
Thus:
The maximum resistance Rload = Rmax = 50 * (Vsupply – 12V).
Figure 2-15. Load Resistance Versus Input Voltage
Series 240/241 Instruction Manual Chapter 2 Installation
IM-24 2-21
Pulse Output Connections The pulse output is used for a remote counter. When the preset volume or
mass (defined in the totalizer settings, see page 3-6) has passed the meter,
the output provides a 50 millisecond square pulse.
The pulse output requires a separate 5 to 36 VDC power supply. The pulse
output optical relay is a normally-open single-pole relay. The relay has a
nominal 200 volt/160 ohm rating. This means that it has a nominal on-
resistance of 160 ohms, and the largest voltage that it can withstand across
the output terminals is 200 volts. However, there are current and power
specifications that must be observed. The relay can conduct a current up to
40 mA and can dissipate up to 320 mW. The relay output is isolated from the
meter electronics and power supply.
Figure 2-16. Isolated Pulse Output with External Power Supply
Optional Backlight Connection The Sierra Model 240 has an optional backlight connection provided. It is in-
tended to be powered by a separate 12 to 36 VDC power supply or by the
pulse power input. Both options are shown below.
The Sierra Model 240 has an optional backlight connection provided. It is in-
tended to be powered by a separate 12 to 36 VDC power supply or by the
pulse
Chapter 2 Installation Series 240/241 Instruction Manual
2-22 IM-24
Remote Electronics Wiring The remote electronics enclosure should be mounted in a convenient, easy to
reach location. For hazardous location installations, make sure to observe
agency requirements for installation. Allow some slack in the interface cable
between the junction box and the remote electronics enclosure. To prevent
damage to the wiring connections, do not put stress on the terminations at
any time.
The meter is shipped with temporary strain relief glands at each end of the
cable. Disconnect the cable from the meter’s terminal block inside the junc-
tion box–not at the remote electronics enclosure. Remove both glands and
install appropriate conduit entry glands and conduit. When installation is
complete, re-connect each labeled wire to the corresponding terminal posi-
tion on the junction box terminal block. Make sure to connect each wire
pair’s shield. Note: incorrect connection will cause the meter to malfunction.
Figure 2-17. Junction Box Sensor Connections
Note: Numeric code in junction box label matches wire labels.
Series 240/241 Instruction Manual Chapter 3 Operation
IM-24 3-1
Chapter 3 Operating Instructions After installing the Innova-Flo Vortex Meter, you are ready to begin op-
eration. The sections in this chapter explain the display/keypad com-
mands, meter start-up and programming. The meter is ready to operate at
start up without any special programming. To enter parameters and sys-
tem settings unique to your operation, see the following pages for in-
structions on using the setup menus.
Flow Meter Display/Keypad The flow meter’s digital electronics allow you to set, adjust and monitor
system parameters and performance. A full range of commands are avail-
able through the display/keypad. The LCD display gives 2 x 16 characters
for flow monitoring and programming. The six push buttons are operable
either directly on the display panel or with a hand-held magnet through
the explosion-proof enclosure.
From the Run Mode, the ENTER key allows
access to the Setup Menus (through a
password screen). Within the Setup Menus,
pressing ENTER activates the current field.
To set new parameters, press the ENTER key
until an underline cursor appears. Use the
���� keys to select new parameters. Press ENTER to continue. (If change is not
alllowed, ENTER has no effect.) All outputs
are disabled when using the Setup Menus.
The ���� keys advance through each screen
of the current menu. When changing a system
parameter, all ���� keys are available to enter
new parameters.
The EXIT key is active within the Setup Menus.
When using a Setup Menu, EXIT returns you to the
Run Mode. If you are changing a parameter and
make a mistake, EXIT allows you to start over.
Display/Keypad
Commands
EXIT ENTER
� �
�
�
SIERRAINSTRUMENTS
INNOVA FLO™
Figure 3-1. Flow Meter Display/Keypad
Chapter 3 Operation Series 240/241 Instruction Manual
3-2 IM-24
Start-Up To begin flow meter operation:
1. Verify the flow meter is installed and wired as described in Chapter
2.
2. Apply power to the meter. At start up, the unit runs a series of self-
tests that check the program configuration and all flow sensing com-
ponents. After completing the self-test sequence, the Run Mode
screens appear.
3. The Run Mode displays flow information as determined by settings
entered in the Display Menu (page 3-5). Press the �� arrow keys to
view the Run Mode screens.
Press the ENTER key from any Run Mode screen to access the Setup
Menus. Use the Setup Menus to configure the meter’s multi-parameter
features to fit your application.
Setup
Menus
Password
ENTER
Mass Flow
Rate
Volume
Flow Rate
Total
ENTER
Press EXIT to return
to Run Mode
Usekeys to access
each item
Run Mode
Screens
To operate the six push buttons through the
display enclosure, use the hand held magnet
as shown at right.
Note
Starting the flow meter
or pressing EXIT will always display the Run
Mode screens.
Series 240/241 Instruction Manual Chapter 3 Operation
IM-24 3-3
Using the Setup Menus
Output
Menu
Display
Menu
Totalizer
Menu
Units
Menu
Diagnostics
Menu
Calibration
Menu
Password
Menu
Password
4-20 mA
Output 1
ENTER
Cycle Time
(sec)
Number of
Digits
Display TC
(sec)
Display
VFlow?
Display
MFlow?
Totaling
Unit per
Pulse
Reset Total
Mass Flow
Unit
Volume
Flow Unit
Sim Vor
Freq
Highest
Velocity
Meter Size
or Pipe ID
Meter Factor
Process
Temp (F)
Density
Ref Density
Set
Password
Serial
Number
Mass Flow
Rate
Volume
Flow Rate
Total
ENTER
Run Mode
Screens
Setup Menus
Display
Total?Viscosity
Vortek Coef
Ck
Low Flow
Cutoff
Programming the Flow Meter
1. Enter the Setup Menu by pressing the ENTER key until prompted for a password. (All
outputs are disabled while using the Setup Menus.)
2. Use the ���� keys to select the password characters (1234 is the factory-set
password). When the password is correctly displayed, press ENTER to continue.
3. Use the Setup Menus described on the following pages to customize the multi-
parameter features of your Innova-Flo Vortex Meter. (The entire lower display line is
available for entering parameters.)
4. To activate a parameter, press ENTER. Use the ���� keys to make selections. Press
ENTER to continue. Press EXIT to save or discard changes and return to Run Mode.
Chapter 3 Operation Series 240/241 Instruction Manual
3-4 IM-24
Output Menu
Password
ENTER
Use
keys to access menus
Output
Menu
4-20mA Output 1
More >
ENTER
Run Mode
< Measure >
None
Mass
Volume
< 4mA = xxxx >
xxxx
< 20mA = xxxx >
xxxx
< TimeConst (sec)
xxxx
Example for Setting an Output
The following shows how to set Output 1 to measure volumetric flow with 4 mA = 0 gal/min and 20 mA = 100
gal/min with a time constant of 5 seconds. (All outputs are disabled while using the Setup Menus.)
First, set the desired units of measurement:
1. Use �� keys to move to the Units Menu (see page 3-8).
2. Press � key until Volume Flow Unit appears. Press ENTER.
3. Press � key until gal appears in the numerator. Press � key to move the underline cursor to the
denominator. Press the � key until min appears in the denominator. Press ENTER to select.
4. Press � key until Units Menu appears.
Second, set the analog output:
1. Use �� keys to move to the Output Menu.
2. Press the � key until 4-20mA Output 1 appears.
3. Press � key to access Measure selections. Press ENTER and press the � key to select Volume. Press ENTER.
4. Press � key to set the 4 mA point in the units you have selected for volume of gal/min. Press ENTER
and use ���� keys to set 0 or 0.0. Press ENTER.
5. Press � key to set the 20 mA point. Press ENTER and use ���� keys to set 100 or 100.0. Press ENTER.
6. Press � key to select the Time Constant. Press ENTER and use ���� keys to select 5. Press ENTER.
7. Press the EXIT key and answer YES to permanently save your changes.
Series 240/241 Instruction Manual Chapter 3 Operation
IM-24 3-5
Display Menu
PasswordENTER
Use
keys to access menus
Display
Menu
Cycle Time(sec)
0
ENTER
Run Mode
Number of Digits
2
Display VFlow?
YES or NO
Display MFlow?
YES or NO
If Cycle Time is set to zero, manual advance is required
Used to set the number of digits displayed after
decimal point
For each parameter:
Select Yes to view parameter in Run Mode
Select No to hide parameter in Run Mode
Display TC(sec)
1TC = Display Time Constant, used to smooth display
Display Total?
YES or NO
Use the Display Menu to set the cycle time for automatic screen sequencing used in the Run Mode,
change the precision of displayed values, smooth the values or enable or disable each item displayed
in the Run Mode screens.
Example for Changing a Run Mode Display Item The following shows how to remove the mass flow screen from the Run Mode screens. Note: all outputs are
disabled while using the Setup Menus.
1. Use �� keys to move to the Display Menu.
2. Press � key until Display MFlow? appears.
3. Press ENTER to select.
4. Press � key until N appears. Press ENTER to select.
5. Press EXIT and then ENTER to save changes and return to the Run Mode.
Chapter 3 Operation Series 240/241 Instruction Manual
3-6 IM-24
Totalizer Menu
Password
ENTER
Use
keys to access menus
Totalizer
Menu
Totaling
Inactive
Mass
Volume
ENTER
Run Mode
(unit)/Pulse
xxxx
Reset Total?
YES or NO
Example:
Maximum flowrate = 600 gallons per minute
(600 gallons per minute = 10 gallons per second)
If unit per pulse is set to 600 gallons per pulse,
the totalizer will pulse once every minute.
If unit per pulse is set to 10 gallons per pulse,
the totalizer will pulse once every second.
Use the Totalizer Menu to configure and monitor the totalizer. The totalizer output is a 50
millisecond (.05 second) positive pulse (relay closed for 50 milliseconds). The totalizer
cannot operate faster than one pulse every 100 millisecond (.1 second). A good rule to
follow is to set the unit per pulse value equal to the maximum flow in the same units per
second. This will limit the pulse to no faster than one pulse every second.
Example for Setting the Totalizer
The following shows how to set the totalizer to track volumetric total gallons. (All outputs are disabled
while using the Setup Menus.)
First, set the desired units of measurement:
1. Use �� keys to move to the Units Menu (see to page 3-8).
2. Press � key until Volume Flow Unit appears. Press ENTER.
3. Press � key until gal appears in the numerator. Press � key to move the underline cursor to the
denominator. Press the � key until min appears in the denominator. Press ENTER to select.
4. Press � key until Units Menu appears.
Second, set the pulse output:
1. Use �� keys to move to the Totalizer Menu.
2. Press the � key until Totaling appears.
3. Press ENTER and press the � key to select Volume. Press ENTER.
4. Press � key to set the gallons per pulse. Press ENTER and use ���� keys to set the pulse
value equal to the maximum flow in the same units per second. This will limit the frequency to 1
Hz. Press ENTER.
5. To reset the totalizer, press � key until Reset Total? appears. Press ENTER and the � key to reset
the totalizer if desired. Press ENTER.
6. Press the EXIT key and answer YES to permanently save your changes.
Series 240/241 Instruction Manual Chapter 3 Operation
IM-24 3-7
Units Menu
Password
ENTER
Use
keys to access menus
Units
Menu
ENTER
Run Mode
lb = pounds
Ston = 2000 pounds
Lton = 2240 pounds
gram = grams
kg = 1000 grams
Mton = Metric Ton = 1000 kg
scf = standard cubic feet
nm3 = normal cubic meters
gal = US gallons
MilG = 1,000,000 US gallons
ImpG = 1.20095 US gallons
bbl = barrels = 42 US gallons
lit = liters
MilL = 1,000,000 liters
m3 = cubic meters
ft3= cubic feet
Mass Flow Unit
lb
Ston
Lton
gram /
kg
Mton
scf
nm3
Volume Flow Unit
gal
MilG
ImpG
bbl /
lit
MilL
m3
ft3
sec
min
hr
day
sec
min
hr
day
Use the Units Menu to configure the flow meter with the desired units of measurement.
(These are global settings and determine what appears on all screens.)
Chapter 3 Operation Series 240/241 Instruction Manual
3-8 IM-24
Diagnostics Menu
PasswordENTER
Usekeys to access menus
Diagnostics
Menu
Sim Vor Freq
xxx
ENTER
Run Mode
Highest Velocity
xxx
Simulate Vortex
Frequency (Hz)
Highest Recorded
Velocity (ft/sec)
Use the Diagnostics Menu to simulate flow and review the highest recorded veloc-
ity in ft/sec.
The simulated vortex frequency is used for testing the meter to verify that the
programming is correct. Enter any value for the sensor input in Hz. The meter
will calculate a flow rate based on the corresponding value and update the analog
output and totalizer pulse output. Note: when your diagnostic work is complete,
make sure to return the simulated frequency to zero to allow the electronics to
use the actual value.
Series 240/241 Instruction Manual Chapter 3 Operation
IM-24 3-9
Calibration Menu
PasswordENTER
Use
keys to access menus
Calibration
Menu
Meter Size
or Pipe ID
ENTER
Run Mode
Meter Factor
xxxx
Vortex Coef Ck
xx
Low Flow Cutoff
xx
Serial Number
xxxxxxxxx
Series 220 - meter size
Series 221 - pipe internal diameter (inches)
Meter calibration constant
Series 220 - pulses/ft3
Series 221 - pulses/ft
Adaptive filter setting
Low Flow Cutoff
setting displayed
in volumetric flow
units (view only)
Process Temp(°F)
xxxUsed to correct Meter Factor for thermal
expansion of meter body for Series 220
Density
xxxUnits are lb/ft3
Ref Density
xxx
Units are lb/ft3. Used for calculation of
standard cubic meters, standard cubic feet,
and normal cubic meters.
Viscosity
xxxUnits are centipoise (Cp)
< Vol (xxx/xxx) >
xxx
< Mass (xxx/xxx)
xxx
Low Flow Cutoff
setting displayed
in mass flow
units (view only)
The Calibration Menu contains the calibration coefficients for the flow meter. These
values should by changed only by properly trained personnel. The Vortex Coef Ck and
Low Flow Cutoff are set at the factory. Consult the factory for help with these settings if
the meter is showing erratic flow rate. The units of measurement used in the Calibration
Menu are preset and are as follows: Density = lbm/ft3, Reference Density = lbm/ft
3,
Viscosity = centipoise.
Chapter 3 Operation Series 240/241 Instruction Manual
3-10 IM-24
Password Menu
PasswordENTER
Usekeys to access menus
Password
Menu
Set Password
1234
ENTER
Run Mode
Use the Password Menu to set or change the system password.
The factory-set password is 1234.
Series 240/241 Instruction Manual Chapter 4 HART Communications
IM-24 4-1
Chapter 4 HART Communications
Wiring
The diagram below details the proper connections required for HART communi-
cations:
Warning!
Place controls in manual
mode when making con-
figuration changes to the
vortex meter.
Chapter 4 HART Communications Series 240/241 Instruction Manual
4-2 IM-24
HART Menus
Online Menu
1 Device Setup
2 PV
3 PV AO
4 PV LRV
5 URV
1 Process Variables
2 Diag/Service
3 Basic Setup
4 Detailed Setup
5 Review
1 Snsr
2 AI % Rnge
3 AO1
1 Distributor
2 Model
3 Dev id
4 Tag
5 Date
6 Write Protect
7 Descriptor
8 Message
9 PV snsr s/n
Final assy #
Revision #'s
1 Test Device
2 Loop Test
3 Calibration
4 D/A Trim
1 Tag
2 PV unit
3 Range Values
4 Device Information
5 PV Xfer fnctn
6 PV Damp
1 PV LRV
2 PV URV
3 PV LSL
4 PV USL
1 Universal Rev
2 Fld dev Rev
3 Software Rev
1 4 mA
2 20 mA
3 Other
4 End
1 Apply Values
2 Enter Values
1 4 mA
2 20 mA
3 Exit
1 PV LRV
2 PV URV
3 PV USL
4 PV LSL
1 Sensors
2 Signal Condition
3 Output Condition
4 Device Information
1 PV
2 PV Sensor Unit
3 Sensor information
1 Snsr Damp
2 URV
3 AI LRV
4 Xfer Fnctn
5 AI % rnge
1 Analog Output
2 HART Output
1 Distributor
2 Model
3 Dev id
4 Tag
5 Date
6 Write Protect
7 Descriptor
8 Message
9 PV snsr s/n
Final assy #
Revision #'s
1 AO1
2 AO alarm typ
3 Loop test
4 D/A trim
5 Scaled D/A trim
1 4 mA
2 20 mA
3 Other
4 End
1 Poll addr
2 Num req. preams
3 Burst mode
4 Burst option
1 Universal Rev
2 Fld dev Rev
3 Software Rev
1 PV LRV
2 PV URV
PV LSL, PV USL, PV Min span
1 PV LRV
2 PV URV
Use password 16363.
Series 240/241 Instruction Manual Chapter 4 HART Communications
IM-24 4-3
Fast Key Sequence Use password 16363.
Sequence Description Access Notes 1,1,1 Snsr View Primary variable value 1,1,2 AI % Rnge View Analog output % range 1,1,3 AO1 View Analog output, mA 1,2,1 Test Device N/A Not used 1,2,2,1 4 mA View Loop test, fix analog output at 4 mA 1,2,2,2 20 mA View Loop test, fix analog output at 20 mA 1,2,2,3 Other Edit Loop test, fix analog output at mA value entered 1,2,2,4 End Exit loop test 1,2,3,1,1 4 mA N/A Not used, apply values 1,2,3,1,2 20 mA N/A Not used, apply values 1,2,3,1,3 Exit Exit apply values 1,2,3,2,1 PV LRV Edit Primary variable lower range value 1,2,3,2,2 PV URV Edit Primary variable upper range value 1,2,3,2,3 PV USL View Primary variable upper sensor limit 1,2,3,2,4 PV LSL View Primary variable lower sensor limit 1,2,4 D/A Trim Edit Calibrate electronics 4mA and 20mAvalues 1,3,1 Tag Edit Tag 1,3,2 PV unit Edit Primary variable units 1,3,3,1 PV LRV Edit Primary variable lower range value 1,3,3,2 PV URV Edit Primary variable upper range value 1,3,3,3 PV LSL View Primary variable upper sensor limit 1,3,3,4 PV USL View Primary variable lower sensor limit 1,3,4,1 Distributor N/A Not used 1,3,4,2 Model N/A Not used 1,3,4,3 Dev id View Device identification 1,3,4,4 Tag Edit Tag 1,3,4,5 Date Edit Date 1,3,4,6 Write Protect View Write protect 1,3,4,7 Descriptor Edit Vortex flowmeter 1,3,4,8 Message Edit 32 character alphanumeric message 1,3,4,9 PV snsr s/n View Primary variable sensor serial number 1,3,4,menu Final assy # Edit Final assembly number 1,3,4,menu,1 Universal Rev View Universal revision 1,3,4,menu,2 Fld dev Rev View Field device revision 1,3,4,menu,3 Software Rev View Software revision 1,3,5 PV Xfer fnctn View Linear 1,3,6 PV Damp Edit Primary variable damping (time constant) in seconds 1,4,1,1 PV View Primary variable value 1,4,1,2 PV Sensor Unit Edit Primary variable units 1,4,1,3 Sensor Information View PV LSL, PV USL, PV Min span 1,4,2,1 Snsr Damp Edit Primary variable damping (time constant) in seconds 1,4,2,2,1 PV LRV Edit Primary variable low range value 1,4,2,2,2 PV URV Edit Primary variable upper range value 1,4,2,3,1 PV LRV Edit Primary variable low range value 1,4,2,3,2 PV URV Edit Primary variable upper range value 1,4,2,4 Xfer Fnctn View Linear 1,4,2,5 AI % rnge View Analog output % range 1,4,3,1,1 AO1 View Analog output, mA 1,4,3,1,2 AO alarm typ N/A Not used
Continued on next page
Chapter 4 HART Communications Series 240/241 Instruction Manual
4-4 IM-24
Sequence Description Access Notes 1,4,3,1,3,1 4 mA View Loop test, fix analog output at 4 mA 1,4,3,1,3,2 20 mA View Loop test, fix analog output at 20 mA 1,4,3,1,3,3 Other Edit Loop test, fix analog output at mA value entered 1,4,3,1,3,4 End Exit loop test 1,4,3,1,4 D/A trim Edit Calibrate electronics 4mA and 20mAvalues 1,4,3,1,5 Scaled D/A trim N/A Not used 1,4,3,2,1 Poll addr Edit Poll address 1,4,3,2,2 Num req. preams View Number of required preambles 1,4,3,2,3 Burst mode N/A Not used 1,4,3,2,4 Burst option N/A Not used 1,4,4,1 Distributor N/A Not used 1,4,4,2 Model N/A Not used 1,4,4,3 Dev id View Device identification 1,4,4,4 Tag Edit Tag 1,4,4,5 Date Edit Date 1,4,4,6 Write Protect View Write protect 1,4,4,7 Descriptor Edit Vortex flowmeter 1,4,4,8 Message Edit 32 character alphanumeric message 1,4,4,9 PV snsr s/n View Primary variable sensor serial number 1,4,4,menu Final assy # Edit Final assembly number 1,4,4,menu,1 Universal Rev View Universal revision 1,4,4,menu,2 Fld dev Rev View Field device revision 1,4,4,menu,3 Software Rev View Software revision 1,5 Review N/A Not used 2 PV View Primary variable value 3 PV AO View Analog output, mA 4,1 PV LRV Edit Primary variable lower range value 4,2 PV URV Edit Primary variable upper range value 5,1 PV LRV Edit Primary variable lower range value 5,2 PV URV Edit Primary variable upper range value
Series 240/241 Instruction Manual Chapter 5 Troubleshooting & Repair
IM-24 5-1
Chapter 5 Troubleshooting and Repair
f fi
G A
A1 A2
A3 A4
Kc It
Kb
V
Re
Ck
Lvl
4-20(1),Zero
xxxx
4-20(1),FScale
xxxx
Factory Defaults
Meter Type
Gain Control
Filter Control
Test Pulse Out
*
Not Present on
220 models*
Reynolds Corr.
Adj. Filter
xx dB
O
I
Pulse Out Queue
xxxxxxxxxx
TOF
G f
Sig. Rev
Micro Rev
AD R T
F PT V
Spi Err
Rcv Sent
Hidden Diagnostics Menus
The menus shown above can be accessed using the password 16363, then mov-
ing to the display that reads “Diagnostics Menu” and pressing ENTER (rather
than one of the arrow keys).
Use the right arrow key to move to the second column. Press EXIT to move
from the second column back to the first, press EXIT while in the first column to
return to the setup menus.
Caution: password 16363 will allow full access to the configuration and should
be used carefully to avoid changes that can adversely alter the function of the
meter.
Each of the menus above will first be defined followed by specific troubleshoot-
ing steps.
Warning!
Before attempting any flow
meter repair, verify that the
line is not pressurized.
Always remove main power
before disassembling any
part of the flow meter.
Chapter 5 Troubleshooting & Repair Series 240/241 Instruction Manual
5-2 IM-24
Column One Hidden Diagnostics Values
• f = vortex shedding frequency (Hz). If an asterisk (*) is dis-
played after the f value, a valid vortex signal is being registered
for the flow.
• fi = adaptive filter – should be approximately 25% higher than
the vortex shedding frequency, this is a low-pass filter. If the
meter is using the Filter Control (see below) in the manual
mode, fi will be displayed as fm.
• G = gain (applied to vortex signal amplitude). Gain defaults to
1.0 and can be changed using the Gain Control (see below).
• A = Amplitude of the vortex signal in Volts rms.
• A1, A2, A3, A4 = A/D counts representing the vortex signal
amplitude. Each stage (A1-A4) cannot exceed 512. Beginning
with stage A1, the A/D counts increase as the flow rate in-
creases. When stage A1 reaches 512, it will shift to stage A2.
This will continue as the flow rate increases until all 4 stages
read 512 at high flow rates. Higher flow rates (stronger signal
strength) will result in more stages displaying 512.
• Kc, It, Kb = profile equation (factory use only). Series 241
only.
• V = calculated average pipe velocity (ft/sec).
• Re = calculated Reynolds number.
• Ck = calculated Ck at current operating conditions. Ck is a
variable in the equation that relates signal strength, density, and
velocity for a given application. It is used for noise rejection
purposes. Ck directly controls the fi value (see above). If the
Ck is set too low (in the calibration menu), then the fi value
will be too low and the vortex signal will be rejected resulting
in zero flow rate being displayed. The calculated Ck value in
this menu can be compared to the actual Ck setting in the cali-
bration menu to help determine if the Ck setting is correct.
• Lvl = threshold level. If the Low Flow Cutoff in the calibra-
tion menu is set above this value, the meter will read zero flow.
The Lvl level can be checked at no flow. At no flow, the Lvl
must be below the Low Flow Cutoff setting or the meter will
have an output at no flow.
• Adj. Filter = adjustable filter. Displays the filtering in deci-
bels. Normally reads zero. If this value is consistently –5 or
–10, for example, the Ck or density setting may be wrong.
• O, I = factory use only.
Series 240/241 Instruction Manual Chapter 5 Troubleshooting & Repair
IM-24 5-3
• Pulse Out Queue = Pulse output queue. This value will accu-
mulate if the totalizer is accumulating faster than the pulse out-
put hardware can function. The queue will allow the pulses to
“catch up” later if the flow rate decreases. A better practice is
to slow down the totalizer pulse by increasing the value in the
(unit)/pulse setting in the totalizer menu.
• TOF, G, f = factory use only.
• Sig. Rev = Signal board hardware and firmware revision.
• Micro Rev = Microprocessor board hardware and firmware re-
vision.
• AD, R, T, F, PT, V = factory use only.
• SPI Err, Rcv, Sent = factory use only.
Column Two Hidden Diagnostics Values
• 4-20(1), Zero = Analog counts to calibrate zero on analog output.
• 4-20(1), FScale = Analog counts to calibrate full scale on analog
output.
• Vor Freq Direct? = Frequency output setting, used by factory dur-
ing calibration. Set to NO if totalizer is used.
• Reynolds Corr. = Reynolds number correction for the flow profile.
Set to Enable for series 241 insertion and set to Disable for series
240 inline.
• Gain Control = Manual gain control (factory use only). Leave set
at 1.0.
• Filter control = Manual filter control. This value can be changed to
any number to force the fi value (which will be displayed as fm) to a
constant. A value of zero activates the automatic filter control
which sets fi at a level that floats above the f value.
• Factory Defaults = Reset to factory defaults. If you change this to
YES and press ENTER, all factory configuration is lost and you
must reconfigure the entire program. Consult the factory before per-
forming this process, it is required only in very rare cases.
• Meter Type = Insertion (model 241) or Inline (model 240) meter.
• Test Pulse Out = Force totalizer pulse. Set to YES and press
ENTER to send one pulse. Very useful to test totalizer counting
equipment.
Chapter 5 Troubleshooting & Repair Series 240/241 Instruction Manual
5-4 IM-24
Analog Output Calibration To check the 4–20 mA circuit, connect a DVM in series with the output
loop. Select zero or full scale (from the second column of the hidden di-
agnostics) and then actuate the enter key twice. This action will cause
the meter to output its 4 mA or 20 mA condition. If the DVM indicates a
current greater than ± 0.006 mA from 4 or 20, adjust the setting up or
down until the output is calibrated. Note: these settings are not for ad-
justing the output zero and span to match a flow range, that function is
located in the Output Menu.
Troubleshooting the Flow Meter Symptom: Output at no Flow
1. The low flow cutoff is set too low. At no flow, go to the first col-
umn of the hidden diagnostics menu and record Lvl value. The low
flow cutoff must be set above this value.
Example: at no flow, Lvl = 25. Set the low flow cutoff in the Cali-
bration Menu to approximately 28 and the meter will no longer read
a flow rate at no flow.
Symptom: Erratic Output
1. The flow rate may be too low, just at the cutoff of the meter range,
and the flow cycles above and below the cutoff making an erratic
output. The meter range is stamped on the label on the outside of
the electronics enclosure cover (based on application conditions
when the meter was ordered). Consult the factory if necessary to
confirm the meter range based on current operating conditions. It
may be possible to lower the low flow cutoff to increase the meter
range. See the example above for output at no flow, only this time
the low flow cutoff is set too high. You can lower this value to in-
crease the meter range as long as you do not create the output at no
flow condition previously described.
2. Mechanical installation may be incorrect. Verify the straight run is
adequate as described in Chapter 2. For in-line meters, make sure
the meter is not installed backwards and there are no gaskets pro-
truding into the flow stream. For insertion meters, verify the inser-
tion depth and flow direction.
3. The meter may be reacting to actual changes in the flow stream. The
output can be smoothed using a time constant. The displayed values
can be smoothed using the time constant in the Display Menu. The
analog outputs can be smoothed using the time constant in the Out-
put Menu. A time constant of 1 will result in the change in value
reaching 63% of its final value in one second. A time constant of 4
is 22%, 10 is 9.5% and 50 is 1.9% of the final value in one second.
The time constant equation is shown below (TC = Time Constant).
Series 240/241 Instruction Manual Chapter 5 Troubleshooting & Repair
IM-24 5-5
4. The vortex coefficient Ck may be incorrectly set. The Ck is a value
in the equation used to determine if a frequency represents a valid
vortex signal given the fluid density and signal amplitude. In prac-
tice, the Ck value controls the adaptive filter, fi, setting. During
flow, view the f and fi values in the first column of the hidden diag-
nostics. The fi value should be approximately 25 % higher than the f
value. If you raise the Ck setting in the Calibration Menu, then the fi
value will increase. The fi is a low pass filter, so by increasing it or
lowering it, you can alter the range of frequencies that the meter will
accept. If the vortex signal is strong, the fi value will increase to a
large number – this is correct.
Symptom: No Output
1. For remote mounted electronics, carefully check all the wiring con-
nections in the remote mount junction box. There are 6 connections
that must be correct, verify each color (black and red), shield, and
wire number.
2. Check the density value in the Calibration Menu to see if it is correct
for the current operating conditions.
3. Using ESD precautions and hazardous area precautions, remove the
electronics enclosure window cover. Disconnect the vortex sensor
from the Signal board. Measure the resistance from each Sensor pin
to the meter ground - each should be open, ( see drawing below).
Measure the resistance from the Ground pin to the meter ground –
this should be grounded to the meter. With the sensor still discon-
nected, go the first column of the hidden diagnostics and display the
vortex shedding frequency, f. Hold a finger on the four exposed pins
on the Signal board. The meter should read electrical noise, 60 Hz
for example. If all readings are correct, re-install vortex sensor
wires.
4. Verify all meter configuration and troubleshooting steps previously
described. There are many possible causes of this problem, consul-
factory if necessary.
% change to final value
in one second = 100 (1 – e(-1/TC))
Chapter 5 Troubleshooting & Repair Series 240/241 Instruction Manual
5-6 IM-24
Electronics Assembly Replacement (All Meters) The electronics boards are electrostatically sensitive. Wear a grounding
wrist strap and make sure to observe proper handling precautions re-
quired for static-sensitive components.
1. Turn off power to the unit.
2. Locate and loosen the small set screw which locks the larger
enclosure cover in place. Unscrew the cover to expose the
electronics stack.
3. Locate the sensor connector that comes up from the neck of
the flow meter and attaches to the circuit board. Use small
pliers to pull the connector off of the circuit board.
4. Locate and loosen the small set screw which locks the smaller enclo-
sure cover in place. Unscrew the cover to expose the field wiring
strip. Tag and remove the field wires.
5. Remove the screws that hold the black wiring label in place, remove
the label.
6. Locate the 4 Phillips head screws which are spaced at 90-degrees
around the terminal board. These screws hold the electronics stack in
the enclosure. Loosen these screws (Note: that these are captive
screws, they will stay inside the enclosure).
7. Carefully remove the electronics stack from the opposite side of the
enclosure. If the electronics stack will not come out, gently tap the
terminal strip with the screw driver handle. This will loosen the rub-
ber sealing gasket on the other side of the enclosure wall. Be careful
that the stack does not hang up on the loose sensor harnesses.
8. Repeat steps 1 through 6 in reverse order to install the new electron-
ics stack.
Warning!
Before attempting any flow
meter repair, verify that the
line is not pressurized.
Always remove main power
before disassembling any
part of the mass flow meter.
Series 240/241 Instruction Manual Chapter 5 Troubleshooting & Repair
IM-24 5-7
Returning Equipment to the Factory Before returning any Innova-Flo meter to the factory, you must re-
quest a Return Material Authorization (RMA) number. To obtain an
RMA number and the correct shipping address, contact Customer Ser-
vice at:
(800) 866-0200 or (831) 373-0200 in the USA,
or +31(0)20-6145810 in Europe.
When contacting Customer Service, be sure to have the meter serial
number and model code.
When requesting further troubleshooting guidance, record the following
values first:
f, fi, G, and A at no flow and during flow if possible.
Pressure, temperature, and flow rate
Series 240/241 Instruction Manual Appendix A Specifications
IM-24 A-1
Appendix A Product Specifications
Accuracy
Process 240 Series In-Line Meters 241 Series Insertion Me-ters
(1)
Variables Liquids Gas & Steam Liquids Gas & Steam
Volumetric Flow Rate
±0.7% of rate over a
30:1 range(2)
±1% of rate over a
30:1 range(2)
±1.2% of rate over a
30:1 range(2)
±1.5% of rate over a
30:1 range(2)
Notes: (1) Accuracies stated are for the total volumetric flow through the pipe.
(2) Nominal rangeability is stated. Precise rangeability depends on fluid
and pipe size.
Repeatability 0.1% of rate.
Response Time Adjustable from 1 to 100 seconds.
Material Compatibility Series 240 In-Line Flow Meter: Any gas, liquid or steam compatible with 316L stainless steel, C276
hastelloy or A105 carbon steel. Not recommended for multi-phase fluids.
Series 241 Insertion Flow Meter: Any gas, liquid or steam compatible with 316L stainless steel. Not
recommended for multi-phase fluids.
Flow rates Typical volumetric flow ranges are given in the following tables. Pre-cise flow range depends on the fluid and pipe size. 241 insertion me-ters are applicable to pipe sizes from 2 inch and above. Consult fac-tory for sizing program.
Air Minimum and Maximum Flow Rates (scfm) (1)
Pressure ½-inch ¾-inch 1-inch 1.5-inch 2-inch 3-inch 4-inch 6-inch 8-inch
0 psig 1.8 17.5
3.3 41.4
5 90
13 241
22 369
50 826
88 1438
198 3258
347 5708
100 psig 5 137
9.2 324
15
701
37
1728
62 2879
138 6447
240 11222
543 25421
952 44536
200 psig 6.8 257
12.6 608
20 1313
50 3234
83 5389
185 12067
322 21006
730 47585
1279 67122
300 psig 8.3 378
15.3 893
24 1924
59 4740
98 7900
240 17687
382 30789
866 48821
1518 64552
400 psig 9.5 500
17.5 1178
27 2535
66 6246
110 10410
247 23308
430 31141
975 46884
1708 61990
500 psig 10.6 620
19.5 1464
29 3147
72 7752
120 12920
270 22592
469 29834
1063 44915
1862 59387
Note: (1) Standard conditions are 70° F and 1 atmosphere.
Steam Minimum and Maximum Flow Rates (lb/hr)
Pressure ½-inch ¾-inch 1-inch 1.5-inch 2-inch 3-inch 4-inch 6-inch 8-inch
5 psig 6.5 51.7
12 122
20 265
49 652
82 1087
183 2434
319 4237
722 9598
1265 16815
100 psig 14.8 270
27.4 639
46 1385
112 3413
187 5688
419 12735
729 24168
1651 50219
2893 87980
200 psig 20 493
37 1164
61 2524
151 6217
252 10362
565 23200
984 40385
2229 91485
3905 160275
300 psig 24 716
44.5 1689
74 3662
182 9021
304 15035
681 33664
1185 58601
2685 132750
4707 232570
400 psig 27.7 940
51 2240
85 4814
209 11859
349 19764
781 44253
1359 77033
3078 174505
5393 305721
500 psig 30.8 1170
57 2761
95 5986
233 14745
389 24575
870 55025
1515 95784
3433 216983
6014 331080
Appendix A Specifications Series 240/241 Instruction Manual
A-2 IM-24
Water Minimum and Maximum Flow Rates
½-inch ¾-inch 1-inch 1.5-inch 2-inch 3-inch 4-inch 6-inch 8-inch
gpm 1 22
1.3 40
2.2 67
5.5 166
9.2 276
21 618
36 1076
81 2437
142 4270
m3/hr .23
5 .3
9.1 0.5 15
1.3 38
2.1 63
4.7 140
8.1 244
18 554
32 970
Linear Range Smart electronics corrects for lower flow down to a Reynolds num-
ber of 5,000. The Reynolds number is calculated using the fluid density and viscosity entered into the memory. Rangeability de-pends on the fluid, process conditions and pipe size. Consult factory for your application. Velocity rangeability under ideal conditions is as follows:
Liquids 30:1 1 foot per second velocity minimum 30 feet per second velocity maximum Gases 30:1 10 feet per second velocity minimum 300 feet per second velocity maximum Process Fluid Pressure
240 Pressure Ratings
Process Connection
Material Rating
Flanged 316L SS, A105 Carbon Steel, C276 Hastelloy 150, 300, 600 lb
Wafer 316L SS, A105 Carbon Steel, C276 Hastelloy 600 lb
241 Pressure Ratings
Probe Seal Process Connection
Material Rating Ordering Code
Compression Fitting
2-inch MNPT
316L SS
ANSI 600 lb
CM
2-inch 150 lb flange 316L SS ANSI 150 lb CF
2-inch 300 lb flange 316L SS ANSI 300 lb CG
2-inch 600 lb flange 316L SS ANSI 600 lb CH
Packing Gland 2-inch MNPT 316L SS 50 psig PM
2-inch 150 lb flange 316L SS 50 psig PF
2-inch 300 lb flange 316L SS 50 psig PG
Packing Gland with Removable Retractor
2-inch MNPT
316L SS
ANSI 300 lb
PM, RR
2-inch 150 lb flange 316L SS ANSI 150 lb PF, RR
2-inch 300 lb flange 316L SS ANSI 300 lb PG, RR
Packing Gland with Permanent Retractor
2-inch MNPT
316L SS
ANSI 600 lb
PMR
2-inch 150 lb flange 316L SS ANSI 150 lb PFR
2-inch 300 lb flange 316L SS ANSI 300 lb PGR
2-inch 600 lb flange 316L SS ANSI 600 lb PHR
Process Fluid and Ambient Temperature Process Fluid: Standard temperature sensor: –40° to 400° F (–40° to 205° C). Medium temperature sensor: 250° to 500° F (120° to 260° C). High temperature sensor: 250° to 750° F (120° to 400° C). Ambient: Operating: –5° to 140° F (–20° to 60° C). Storage: –40° to 150° F (–40° to 65° C). 0-98% relative humidity, non-condensing conditions.
Series 240/241 Instruction Manual Appendix A Specifications
IM-24 A-3
Power Requirements Loop powered, 12 to 36 VDC. Output Signals Analog: field rangeable linear, 4-20 mA output signal, 1000 ohms
maximum loop resistance, selected by user for volumetric flow rate or mass flow rate.
Pulse: field rangeable volume/pulse output for totalization is a 50-
millisecond duration pulse operating a solid-state relay capable of switching 40 VDC, 40 mA maximum.
Display Alphanumeric 2 x 16 LCD digital display. Six push buttons (up, down, right, left, enter, exit) operable either
directly on the display panel or with a hand-held magnet through the display glass of the explosion-proof enclosure.
Viewing at 90° mounting intervals.
Totalizer Based on user-determined flow units, six significant figures in sci-
entific notation. Total stored in non-volatile memory. Wetted Materials Series 240 In-Line Flow Meter: 316L stainless steel standard. C276 hastelloy or A105 carbon steel optional. Series 241 Insertion Flow Meter: 316L stainless steel standard. Teflon
® packing gland below 500° F (205° C).
Graphite packing gland above 500° F (205° C). Enclosure NEMA 4X cast enclosure. Electrical Ports Two 3/4-inch female NPT ports. Mounting Connections Series 240: Wafer or 150, 300, 600 lb ANSI flange. Series 241 Permanent installation: 2-inch MNPT; 150, 300, 600 lb
ANSI flange with compression fitting probe seal. Series 241 Hot Tap
(1) Installation: 2-inch MNPT; 150, 300, 600 lb
ANSI flange and optional retractor with packing gland probe seal. Note: (1) Removable under line pressure. Mounting Position
(1) Series 240 In-Line Flow Meter: No effect.
Series 241 Insertion Flow Meter: Meter must be perpendicular within ± 5° of the pipe centerline.
Note: (1) For liquid applications, pipeline must remain full at all times.
Certifications Construction Inspection ( ANSI/ASME B31.3). Materials (NACE MR-01-75[90]). CE and FM approved. CSA, CENELEC approval pending. FM approvals: Class I, Division 1, Groups B, C, & D, T6 at Tamb = 60°C Class II/III, Division 1, Groups E, F, & G IP66, NEMA 4X
Series 240/241 Instruction Manual Appendix B Glossary
IM-24 B-1
Appendix B Glossary
A B C D A Cross sectional area. acfm Actual cubic feet per minute (volumetric flow rate). ASME American Society of Mechanical Engineers. Bluff Body A non-streamlined body placed into a flow stream to
create vortices. Also called a Shedder Bar. BTU British Thermal Unit, an energy measurement. Cenelec European Electrical Code. Compressibility A factor used to correct for the non-ideal changes in Factor a fluid’s density due to changes in temperature
and/or pressure. CSA Canadian Standards Association. d Width of a bluff body or shedder bar. D Diameter of a flow channel.
E F G H f Frequency of vortices generated in a vortex flow meter, usually in Hz. Flow Channel A pipe, duct, stack, or channel containing flowing fluid. Flow Profile A map of the fluid velocity vector (usually non-
uniform) in a cross-sectional plane of a flow channel (usually along a diameter).
FM Factory Mutual. Ft Foot, 12 inches, a measure of length. Ft^2 Square feet, measure of area. Ft^3 Cubic feet, measure of volume. gpm Gallons per minute. Hz Hertz, cycles per second.
Appendix B Glossary Series 240/241 Instruction Manual
B-2 IM-24
I J K L In-Line Flow Meter A flow meter which includes a short section of piping
which is put in-line with the user’s piping. Insertion Flow Meter A flow meter which is inserted into a hole in the
user’s pipeline. Joule A unit of energy equal to one watt for one second.
Also equal to a Newton-meter. LCD Liquid crystal display.
M N O P m Mass flow rate.
mA Milli-amp, one thousandth of an ampere of current.
µ Viscosity, a measure of a fluid’s resistance to shear stress. Honey has high viscosity, alcohol has low viscosity.
∆P Permanent pressure loss.
P Line pressure (psia or bar absolute).
ρ act The density of a fluid at the actual temperature and
pressure operating conditions.
ρ std The density of a fluid at standard conditions (usually
14.7 psia and 20° C). Permanent Unrecoverable drop in pressure. Pressure Loss Piezoelectric Crystal A material which generates an electrical charge
when the material is put under stress. PRTD An resistance temperature detector (RTD) with plati-
num as its element. Used because of high stability. psia Pounds per square inch absolute (equals psig + atmospheric pressure). Atmospheric
pressure is typically 14.696 psi at sea level. psig Pounds per square inch gauge.
PV Liquid vapor pressure at flowing conditions (psia or
bar absolute).
Series 240/241 Instruction Manual Appendix B Glossary
IM-24 B-3
Q R S T Q Flow rate, usually volumetric. Rangeability Highest measurable flow rate divided by the lowest
measurable flow rate. Reynolds Number A dimensionless number equal to the density of a fluid or Re times the velocity of the fluid times the diameter of the
fluid channel, divided by the fluid viscosity (i.e., Re =
ρVD/µ). The Reynolds number is an important number for vortex flow meters because it is used to determine the minimum measurable flow rate. It is the ratio of the inertial forces to the viscous forces in a flowing fluid.
RTD Resistance temperature detector, a sensor whose
resistance increases as the temperature rises. scfm Standard cubic feet per minute (flow rate converted
to standard conditions, usually 14.7 psia and 20° C). Shedder Bar A non-streamlined body placed into a flow stream to
create vortices. Also called a Bluff Body. Strouhal Number A dimensionless number equal to the frequency or St of vortices created by a bluff body times the width of
the bluff body divided by the velocity of the flowing fluid (i.e., St = fd/V). This is an important number for vortex flow meters because it relates the vortex fre-quency to the fluid velocity.
Totalizer An electronic counter which records the total accu-
mulated flow over a certain range of time. Traverse The act of moving a measuring point across the
width of a flow channel.
U V W X Y Z Uncertainty The closeness of agreement between the result of a
measurement and the true value of the measurement. V Velocity or voltage. VAC Volts, alternating current. VDC Volts, direct current. VORTEX An eddy of fluid.
Series 240/241 Instruction Manual Appendix C ATEX-IECEx Specifications
IM-24 C-1
Appendix C
ATEX-IECEx Specifications
NEN EN IEC 60079-0 (2004) Electrical Apparatus for explosive gas atmospheres General Requirements NEN EN IEC 60079-1 (2007) Electrical Apparatus for explosive gas atmospheres Flameproof enclosures “d” NEN EN IEC 61241-0 (2006) NEN EN IEC 61241-1 (2004) Directive 94/9/EC (1994) Equipment Intended for use in Potentially Explosive Atmospheres (ATEX) Cable entries are ¾ NPT.
0344
II 2 G Ex d IIB + H2 T6 II 2 D Ex tD A21 IP66 T85°C KEMA 08ATEX0143
Ex d IIB + H2 T6 Ex tD A21 IP66 T85°C IECEx KEM 08.0028 MANUFACTURED BY: Sierra Instruments 5 Harris Court, Building L Monterey, CA 93940 NOTE: The DATE of manufacture is included in the Serial Number Field. Example: XXXXXX-XXXX-yyyy; 101486-2391-2009 would indicate Serial Number 101486-2391 manufactured in 2009.